Air Conditioning System –

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AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM

AC1


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PRECAUTIONS FOR SERVICING R134a AIRCONDITIONERS1. USE OF NEW REFRIGERANT R134a

The very different characteristics of refrigerantsR134a and R12 have determined the design of theirrespective air conditioning systems. Under no circum stances allow R12 to enter an R134a system, or viceversa, because serious damage could occur.

GENERAL DESCRIPTIONNEW AIR CONDITIONING SYSTEM WITHR134a

Refrigerant R12 (CFC12), previously used in automo biles air conditioning systems is believed to contribute

towards the depletion the earths ozone layer. Theozone layer help to protect us against the harmfulultraviolet rays of the sun.

2. USE OF PROPER COMPRESSOR OILCompressor oil used in conventional R12 air condi tioning systems cannot be used in R 134a air condi tioning systems.Always use genuine Toyota R1 34a air conditioning oilN D OIL 8, made expressly for use with R 1 34a.

If even a small amount of the wrong oil is changed, itwill result in clouding of the refrigerant.A large amount will cause the compressor to seize up.

A newly developed refrigerant, R134 a (HFC 134 a),does not the destroy the ozone layer.

AIR CONDITIONING SYSTEM GENERAL DESCRIPTIONAC2


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4. TIGHTEN CONNECTING PARTS SECURELYSecurely tighten the connecting parts to prevent leak ing of refrigerant gas.Apply a few drops of compressor oil to 0ringfittings for easy tightening and to prevent leakingof refrigerant gas.CAUTION: Apply only NDOIL 8 compressor oilTighten the nuts using 2 wrenches to avoid twist

ing the tube.Tighten the 0ring fittings or the bolted typefittings to the specified torque.

5. INSERT PLUG IMMEDIATELY IN DISCONNECTEDPARTSInsert a plug immediately in the disconnected parts toprevent the ingress of moisture and dust.

6. DO NOT REMOVE PLUG FROM NEW PARTS UNTILIMMEDIATELY BEFORE INSTALLATION

3. USE OF PROPER O RINGS AND SEALS0rings and seals used for conventional R12 airconditioning systams cannot be used for R134a airconditioning systems.Always use genuine Toyota R 134a system 0ringsand seals for R 1 34a air conditioning systems.

7. DISCHARGE GAS IN NEW COMPRESSOR FROMCHARGING VALVE BEFORE INSTALLING ITIf the gas in the new compressor is not dischargedfirst, compressor oil will spray out with gas when theplug is removed.

If Orings and/or seals for R1 2 air conditioning sys tems are used by mistake in the connections of an R134a air conditioning system, the Oring and sealswill foam and swell resulting in leakage of refrigerant.



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3. BE CAREFUL THAT LIQUID REFRIGERANT DOESNOT GET IN YOUR EYES OR ON YOUR SKINIf liquid refrigerant gets in your eyes or on your skin:

(a) Wash the area with lots of cool water.CAUTION: Do not rub your eyes or skin.

(b) Apply clean petroleum jelly to the skin.(c) GO immediately to a physician or hospital for profes

sional treatment.

HANDLING PRECAUTIONS FORREFRIGERANT CONTAINER1. NEVER HEAT CONTAINER OR EXPOSE IT TO

NAKED FLAME2. BE CAREFUL NOT TO DROP CONTAINER AND NOT

TO APPLY PHYSICAL SHOCKS TO IT

HANDLING PRECAUTIONS FORREFRIGERANT1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED

AREA OR NEAR AN OPEN FLAME2. ALWAYS WEAR EYE PROTECTION

CHARGING AND LEAKCHECK METHODSEvacuate the refrigeration system according to thefollowing procedures.

Fill refrigerant in gas state untilgauge pressure reads 1 kglcm2Abnormal indication of

manifold gauges

Check and correctpipe joints

RefrigerantCharge

RefrigerantCharge

StartEvacuation

StopEvacuation

Leave for 5 min.

Gas LeakCheck

AirtightCheck

10 min.



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CAUTION: Be sure to connect both the high and low pressure

quickconnectors onto the A/C system when evacuating. If only one side is connected, the systemwould be open to atmosphere through the otherconnector, making it impossible to maintainvacuum.

Be sure to turn off the manifold gauge valve immediately after evacuating the system. Then you mayswitch off the vacuum pump.

PRECAUTIONS WHEN CHARGINGREFRIGERANT1. DO NOT OPERATE COMPRESSOR WITHOUT

ENOUGH REFRIGERANT IN REFRIGERANTSYSTEMIf there is not enough refrigerant in the refrigerant

system oil lubrication will be insufficient and compres sor burnout may occur, so take care to avoid this.2. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE

WHILST COMPRESSOR IS OPERATINGIf the high pressure valve is opened, refrigerant flowsin the reverse direction and could cause the chargingcylinder to rupture, so open and close the low pres sure valve only.

3. BE CAREFUL NOT TO OVERCHARGE WITH REFRIGERANT IN SYSTEMIf refrigerant is overcharged, it causes problems such

as insufficient cooling, poor fuel economy, engineoverheating etc.

ELECTRICAL PARTSBefore removing and inspecting the electrical parts,set the ignition switch to the LOCK position anddisconnect the negative () terminal cable from bat tery.CAUTION: Work must be started after 90 seconds fromthe time the Ignition switch is turned to the LOCKposition and the negative () terminal cable is disconnected from the battery.



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SUPPLEMENTAL RESTRAINT SYSTEM(SRS)

Failure to carry out service operations in the correctsequence could cause the supplemental restraintsystem to deploy, possibly leading to a serious acci dent.

During removal or installation of the parts and theyellow wire harness and connector for the airbag isnecessary, refer to the precautionary notices in the RSsection before performing the operation.CAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the LOCKposition and the negative () terminal cable is disconnected from the battery.



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DESCRIPTIONPARTS LOCATION

AIR CONDITIONING SYSTEM DESCRIPTIONAC8


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ELECTRICAL WIRING DIAGRAM(Lever Type On 5SFE Engine Model)



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(Push Button Type On 5SFE Engine Model)



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(Lever Type On 1 MZFE Engine Model)



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(Push Button Type On 1 MZFE Engine Model)



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DAMPERS POSITION



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PREPARATIONSST (SPECIAL SERVICE TOOLS)

(0711758070) TJoint

(0711778050) Refrigerant Charging Gauge

(0711758080) Quick Coupler

(0711788070) Refrigerant Charging Hose

(0711758090) Quick Coupler

(0711788060) Refrigerant Charging Hose

(0711788080) Refrigerant Charging Nose

(0711758060) Refrigerant Drain Service Valve

Suction (diam. 13 mm)

Discharge (diam. 16 mm)

Suction (Blue)

Discharge (Red)

Utility (Green)

0711638360 Gas Leak Detector Assembly

0711058060 Air Conditioner Service Tool Set

0711266040 Magnetic Clutch Remover

0711276060 Magnetic Clutch Stopper

0711484020 Snap Ring Pliers

AIR CONDITIONING SYSTEM PREPARATIONAC19


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RECOMMENDED TOOL0908200050 TOYOTA Electrical Tester Set

When replacing compressor

When replacing evaporator

When replacing condenser

NDOIL 8 or equivalent

When replacing receiver

LUBRICANT

10 cc (0.34 fl.oz.)

140 cc (4.9 fl.oz.)

40 cc (1.4 fl.oz.)

40 cc (1.4 f I.oz.)

Compressor oil

ClassificationCapacityItem

AIR CONDITIONING SYSTEM PREPARATIONAC20


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USE OF MANIFOLD GAUGE SETMANIFOLD GAUGE SET INSTALLATION1. CONNECT CHARGING HOSES TO MANIFOLD

GAUGE SETTighten the nuts by hand.CAUTION: Do not connect the wrong hoses.

2. CONNECT QUICK CONNECTORS TO CHARGINGHOSESTighten the nuts by hand.

3. CLOSE BOTH HAND VALVES OF MANIFOLDGAUGE SET

4. REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINE

MANIFOLD GAUGE SET REMOVAL1. CLOSE BOTH HAND VALVES OF MANIFOLD

GAUGE SET2. DISCONNECT QUICK CONNECTORS FROM SER

VICE VALVES ON REFRIGERANT LINEHINT: Slide the sleeve of the quick connector upwardto unlock the connector and remove it from the ser vice valve.

3. INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINE

5. CONNECT QUICK CONNECTORS TO SERVICEVALVESHINT: Push the quick connector onto the servicevalve, then slide the sleeve of the quick connectordownward to lock it.

AIR CONDITIONING SYSTEM USE OF MANIFOLD GAUGE SETAC21


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W i r i n g o r

W i r i n g

C o n n e c t

i o n

E x p a n s i o n

V a l v e

( R e p

l a c e

)

A / C C o n

t r o l A s s e m

b l y

A i r o u

t l e t

S e r v o m o t o r

C o n

d e n s e r

F a n

M o t o r

A i r I n l e t S e r v o m o t o r

M a g n e

t C l u t c h

B l o w e r

R e s

i s t o r

A / C A m p l

i f i e r

B l o w e r

M o t o r

C o m p r e s s o r

E v a p o r a

t o r

C o n

d e n s e r

R e c e i v e r

AC57 AC58 AC47AC67 AC49 AC45 AC53AC56 AC66AC55 AC36 AC36AC59

AIR CONDITIONING SYSTEM TROUBLESHOOTINGAC23


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REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET

This is a method in which the trouble is located by using a manifold gauge set.(See USE OF MANIFOLD GAUGE SET on page AC21 )Read the manifold gauge pressure when the following conditions are established:(a) Temperature at the air inlet with the switch set at RECIRC is 30 35 _ C (86 95 _ F)

(b) Engine running at 1,500 rpm(c) Blower speed control switch set at high(d) Temperature control set at max. cool

HINT: It should be noted that the gauge indications may vary slightly due to ambient temperatureconditions.

1. NORMALLY FUNCTIONING REFRIGERATION SYSTEMGauge reading:

Low pressure side:0.15 0.25 MPa (1.5 2.5 kgf/cm)

High pressure side:1.37 1.57 MPa (14 16 kgf/emt)



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(1) Check for gas leakagewith leak detector andrepair if necessary

(2) Charge refrigerant toproper arhount

(3) If pressure indicatedvalue is near 0 whenconnected to gauge,create the vacuum af ter inspecting and re pairing the location ofthe leak

Drier in oversaturatedstate

Moisture in refrigerationsystem freezes at expan sion valve orifice andblocks circulation of re frigerant

Moisture entered in re frigeration systemfreezes at expansionvalve orifice and tempo rarily stops cycle, butnormal state is restoredafter a time when the icemelts

(1) Replace receiver/drier(2) Remove moisture in

cycle through repeat edly evacuating air

(3) Charge new refrigerantto proper amount

Pressure low on bothlow and high pressuresides

Bubbles seen in sightglass continuously

Insufficient cooling per formance

During operation, prea sure on low pressureside sometimesbecomes a vacuumand sometimes normal

2. MOISTURE PRESENT IN REFRIGERATION SYSTEM

Insufficient refrigerant insystem1

Refrigerant leaking

Condition: Periodically cools and then fails to cool

Gas leakage at someplace in refrigeration sys tem

3. INSUFFICIENT REFRIGERANT

Symptom seen inrefrigeration system

Condition: Insufficient cooling


Probable cause

Probable cause

Diagnosis

Diagnosis

Remedy

Remedy



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(1) Check heat sensingtube, expansion valveand EPR

(2) Clean out dirt in expan sion valve by blowingwith airIf not able to removedirt, replace expansionvalve

(3) Replace receiver(4) Evacuate air and

charge new refrigerantto proper amount.For gas leakage from

heat sensing tube, re place expansion valve.

Refrigerant flow ob structed by moisture ordirt in refrigeration sys tem

Refrigerant flow ob structed by gas leakagefrom expansion valveheat sensing tube

Vacuum indicated onlow pressure side, verylow pressure indicatedon high pressure side

Frost or dew seen onpiping before and afterreceiver/drier or expan sion valve

Condition: Does not cool (Cools from time to time in some cases)

Pressure low on bothlow and high pressuresides

Frost on tubes from re-ceiver to unit

5. REFRIGERANT DOES NOT CIRCULATE

4. POOR CIRCULATION OF REFRIGERANT

Refrigerant flow ob structed by dirt in re ceiver

Refrigerant does not cir culate




Diagnosis

R e c e i v e rclogged

Replace receiv-er

Probable cause

Probable cause

Diagnosis

Remedy

Remedy



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(1) Clean condenser(2) Check fan motor oper ation

(3) If (1) and (2) are in nor mal state, checkamount of refrigerantCharge proper amountof refrigerant

Excessive refrigerant incycle refrigerant over charged:

Condenser cooling insuf ficient condenser finsclogged or fan motorfaulty

Pressure too high onboth low and highpressure sides

No air bubbles seenthrough the sight glasseven when the enginerpm is lowered.

6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER

Unable to develop suffi cient performance due toexcessive refrigerant insystem

.Insufficient cooling ofcondenser


The low pressure pipingis hot to the touch

Bubbles seen in sightglass

(1) Check compressor oilto see if dirty or insuffi cient

(2) Evacuate air andcharge new refrigerant

Air present in refrigera tion system

Insufficient vacuumpurging

7. AIR PRESENT IN REFRIGERATION SYSTEM

Condition: Does not cool down sufficiently

Condition: Does not cool sufficiently

Air entered in refrigera tion system



Probable cause

Probable cause

Diagnosis

Diagnosis

Remedy

Remedy



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8. EXPANSION VALVE IMPROPERLYMOUNTED/HEAT SENSING TUBE DEFECTIVE(OPENS TOO WIDE)


Frost or large amountof dew on piping on lowpressure side

(1) Check heat sensingtube installed condition

(2) If (1) is normal, checkexpansion valveReplace if defective

Excessive refrigerant inlow pressure piping

Expansion valve openedtoo wide

Compression defective

Valve leaking or broken,sliding parts

Pressure too high onlow pressure side

Pressure too low onhigh pressure side

Trouble in expansionvalve or heat sensingtube not installed cor rectly

9. DEFECTIVE COMPRESSION COMPRESSOR

Internal leak in compres sor

Repair or replace com pressor


Symptom seen inref rigeration system


Condition: Does not cool

Probable cause

Probable cause

Diagnosis

Diagnosis Remedy

Remedy



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REFRIGERANT VOLUMEREFRIGERANT VOLUME INSPECTION1. RUN ENGINE AT IDLE SPEED2. OPERATE A/C AT MAXIMUM COOLING FOR A

FEW MINUTES3. INSPECT AMOUNT OF REFRIGERANT

OBSERVE THE SIGHT GLASS ON THE LIQUID TUBE.

*: Bubbles in the sight glass with ambient temperatu ers higher can be considered normal if cooling issuff icient.

REFRIGERANT CHARGE VOLUMESpecified amount:

850 50 g (29.98 1.76 oz)

(1) Check for gas lakage with gas leaktester and repair if necessary

(2) Add refrigerant until bubbles dis apear

(1) Check for gas leakage with gas lea

ktester and repair if necessary(2) Add refrigerant until bubbles disap pear

(1) Discharge refrigrant(2)Evacuate air and charge proper amo

unto of purified refrigerant

Immediately after air conditioning isturned off, refrigerant in sight glassstays clear

When air conditioning is turned off, re frigerant foams and then stay clear

Temperature between compressor inletand outlet is noticeably different

No temperature difference betweencompressor inlet and outlet

No bubbles present in sight glass

Bubbles present insight glass

None, sufficient or too much

Empty or nearly empty

Amount of refrigerant

Refer to items 3 and 4

Refer to items 5 and 6Proper or too much

Too much

Insufficient

Symptom Remedy

Proper

Item

AIR CONDITIONING SYSTEM REFRIGERANT VOLUMEAC29


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2. INSPECT DRIVE BELT TENSIONUsing a belt tension gauge, check the drive belt ten sion.Belt tension gauge:Nippondenso BTG20 (9550600020) orBorroughs No. BT3373FDrive belt tension:

5S FE:New belt 165 26 IbfUsed belt 110 11 lbf1 MZFE:New belt 165 26 lbfUsed belt 88 22 lbfHINT: New belt refers to a belt which has been used

less than 5 minutes on a running engine. Used belt refers to a belt which has beenused

on a running engine for 5 minutes or more. After installing the drive belt, check that it fits

properly in the ribbed grooves.

IDLEUP SPEEDIDLE UP SPEED INSPECTION1. WARM UP ENGINE2. INSPECT IDLE SPEED

5S FE:

DRIVE BELT TENSIONDRIVE BELT TENSION INSPECTION1. INSPECT DRIVE BELTS INSTALLATION CONDI

TIONCheck that the drive belt fits properly in the ribbedgrooves.

Standard idle speed (rpm)

Standard idle speed (rpm)Magnet clutch condition

Magnet clutch condition

Approx. 850

Approx. 750

Approx. 700

Approx. 700

1 MZ FE:

No engaged

No engaged

Engaged

Engaged

AIR CONDITIONING SYSTEM DRIVE BELT TENSIONAC30


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ONVEHICLE INSPECTION1. INSPECTION HOSE AND TUBE CONNECTIONS FOR

LOOSENESS

2. INSPECT HOSES AND TUBES FOR LEAKAGEUsing a gas leak tester, check for leakage of refriger ant.

REFRIGERANT LINESTIGHTENING TORQUE OF REFRIGERATION LINES

AIR CONDITIONING SYSTEM REFRIGERANT LINESAC31


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REFRIGERANT LINES REPLACEMENT1. DISCHARGE REFRIGERANT IN REFRIGERATION

SYSTEM(See page AC21 )

2. REPLACE FAULTY TUBE OR HOSEHINT: Cap the open fittings immediately to keep mois

ture or dirt out of the system.3. TORQUE CONNECTIONS TO SPECIFIED TORQUE

NOTICE: Connections should not be torque tighter thanthe specified torque.

4. EVACUATE AIR IN REFRIGERATION SYSTEM ANDCHARGE WITH REFRIGERANTSpecified amount:

850 50g (29.98 1.76 oz)5. INSPECT FOR LEAKAGE OF REFRIGERANT

Using a gas leak tester, check for leakage of refriger ant.

6. INSPECT AIR CONDITIONING OPERATION

AIR CONDITIONING SYSTEM REFRIGERANT LINESAC32


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3. DISCONNECT WATER VALVE CONTROL CABLEFROM WATER VALVE

4. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES

5. REMOVE INSTRUMENT PANEL AND REINFORCEMENT(See page BO108 )

6. REMOVE BLOWER UNIT(See page AC35 )

AIR CONDITIONING UNITA/C UNIT REMOVAL1. DISCHARGE REFRIGERANT FROM REFRIGERA

TION SYSTEM(See page AC21 )

2. DRAIN ENGINE COOLANT FROM RADIATORHINT: It is not necessary to drain out all the coolant.

7. DISCONNECT LIQUID AND SUCTION TUBE FROMBLOCK JOINTRemove 2 bolts and both tubes.

8. REMOVE REAR AIR DUCTSRemove the clip and the air duct.

9. REMOVE HEATER PROTECTORRemove the 2 clips and the heater protector.

AIR CONDITIONING SYSTEM AIR CONDITIONING UNITAC33
http://bo.pdf/http://bo.pdf/


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BLOWER UNIT INSTALLATION1. INSTALL BLOWER UNIT(a) Install the blower unit with the 3 screws and the nut.(b) Connect the air inlet damper control cable to the

blower unit.(c) Connect the connector.2. INSTALL CONNECTOR BRACKET3. INSTALL ECU BRACKET AND ECU

4. INSTALL GLOVE COMPARTMENT

BLOWER UNITBLOWER UNIT REMOVAL1. REMOVE GLOVE COMPARTMENT

(See page BO108 )2. REMOVE ECU AND ECU BRACKET

3. REMOVE CONNECTOR BRACKET(a) Disconnect the connector from the connector brack

et.(b) Remove the 2 screws and the bracket.

4. REMOVE BLOWER UNIT(a) Disconnect the connector from the blower unit.(b) Disconnect the air inlet damper control cable.(c) Remove the 3 screws, nut and the blower unit.

AIR CONDITIONING SYSTEM BLOWER UNITAC35


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Compressor:1. INSTALL MANIFOLD GAUGE SET

(See page AC21 )2. START ENGINE3. INSPECT COMPRESSOR FOR METALLIC SOUND

Check that there is a metallic sound from the com pressor when the A/C switch is turn on.If metallic sound is heard, replace the compressor

assembly.4. INSPECT PRESSURE OF REFRIGERATION SYSTEMSee Refrigerant System Inspection with ManifoldGauge Set on page AC24 .

5. STOP ENGINE6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER

ANT FROM SAFETY SEALIf there is any leakage, replace the compressor assem bly.

COMPRESSORONVEHICLE INSPECTIONMagnet Clutch:1. MAKE THE FOLLOWING VISUAL CHECKS:

Leakage of grease from the clutch bearing.

Signs of oil on the pressure plate or rotor.Repair or replace, as necessary.2. INSPECT MAGNET CLUTCH BEARING FOR NOISE(a) Start engine.(b) Check for abnormal noise from near the compressor

when the A/C switch is OFF.If abnormal noise is being emitted, replace the mag netic clutch.

3. INSPECT MAGNET CLUTCH(a) Disconnect the connector from the magnet clutch.(b) Connect the positive (+) lead from the battery to the

terminal on the magnetic clutch connector and thenegative () lead to the body ground.

(c) Check that the magnet clutch is energized.If operation is not as specified, replace the magnetclutch.

AIR CONDITIONING SYSTEM COMPRESSORAC36


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1. RUN ENGINE AT IDLE SPEED WITH A/C ON FORAPPROX 10 MINUTES

2. STOP ENGINE

3. DISCONNECT NEGATIVE () CABLE FROM BATTERYCAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the LOCKposition and the negative () terminal cable is disconnected from the battery.

4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM(See page AC21 )

6. DISCONNECT DISCHARGE HOSE AND SUCTIONHOSE FROM COMPRESSOR

7. DISCONNECT CONNECTOR FROM MAGNETCLUTCH

8. REMOVE COMPRESSOR(a) Loosen the drive belt.(b) Remove 3 bolts and compressor.

COMPRESSOR REMOVAL5SFE Engine Model:



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1. RUN ENGINE AT IDLE SPEED WITH A/C ON FORAPPROX 10 MINUTES

2. STOP ENGINE3. DISCONNECT NEGATIVE () CABLE FROM BAT

TERYCAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the LOCKposition and the negative () terminal cable is disconnected from the battery.

COMPRESSOR REMOVAL1 MZFE Engine Model:



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4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM(See page AC21 )

5. DISCONNECT DISCHARGE HOSE AND SUCTIONHOSE FROM COMPRESSOR

6. DISCONNECT CONNECTOR FROM MAGNETCLUTCH

7. REMOVE DRIVE BELTLoosen the pivot bolt and adjusting lock bolt andremove the drive belt.

8. REMOVE COMPRESSOR(a) Remove 2 nuts and 2 bolts.(b) Remove the compressor.



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1. REMOVE PRESSURE PLATE(a) Using SST and socket wrench, remove the shaft bolt.

SST 07112 76060

(b) Install a SST on the pressure plate.SST 0711266040

MAGNET CLUTCH DISASSEMBLY



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2. REMOVE ROTOR(a) Using SST, remove the snap ring.

SST 0711484020CAUTION: Do not spread the point of SST widely.Max width:

23.1 mm

3. REMOVE STARTER(a) Disconnect the stator lead wire from the compressor

housing.

(b) Using a plastic hammer, tap the rotor off the shaft.NOTICE: Be careful not to damage the pulley when tapping on the rotor.

(c) Using SST and socket wrench, remove the pressureplate.SST 0711276060

(d) Remove the shims from the pressure plate.



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MAGNET CLUTCH ASSEMBLY1. INSTALL STATOR(a) Install the stator on the compressor.

NOTICE: The snap ring should be installed so that itsbeveled side faces up.

(b) Using SST, install the new snap ring.SST 07114 84020

(b) Using a SST, remove the snap ring.SST 0711484020

(c) Remove the stator.



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2. INSTALL ROTOR(a) Install the rotor on the compressor shaft.(b) Using SST, install the new snap ring.

SST 0711484020CAUTION:Do not spread the point of SST widely.Max width:

23.1 mm

(c) Using SST and torque wrench, fasten the magnetclutch lead wire to the cylinder block.Torque: 3.4 Nm (35 kgf.cm, 30 in.lbf)SST 0711061050

(b) Using SST and torque wrench, install the shaft bolt.SST 0711276060Torque: 13 Nm (135 kgfcm, 10 ftlbf)

NOTICE: The snap ring should be installed so that itsbeveled side faces up.

3. INSTALL PRESSURE PLATE(a) Put the shims on the pressure plate.



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RECEIVERONVEHICLE INSPECTION

INSPECT FITTINGS FOR LEAKAGEUsing a gas leak tester, check for leakage.If there is leakage, check the tightening torque at the

joints.

RECEIVER REMOVAL1. DICHARGER REFRIGERANT FROM REFRIGERA


3. REMOVE RECEIVER FROM RECEIVER HOLDERRemove the bolt, then remove the receiver from re ceiver holder.NOTICE: Cap the open fittings immediately to keeps moisture out of the system.

2. REMOVE 2 LIQUID TUBES FROM RECEIVERRemove the 2 bolts and the both tubes from thereceiver.

AIR CONDITIONING SYSTEM RECEIVERAC45


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RECEIVER INSTALLATION1. INSTALL RECEIVER INTO RECEIVER HOLDER

Install the receiver into the receiver, holder with thebolt.

2. INSTALL 2 LIQUID TUBES TO RECEIVERInstall 2 liquid tubes to the receiver with 2 bolts.

Torque: 5.5 Nm (55 kgfcm, 48 in.lbf)NOTICE: Do not remove the caps until the tubes areconnected.

3. REPLENISH COMPRESSOR OIL IF RECEIVER HASBEEN REPLACEDAdd 15 cc (0.5 fl.oz.)Compressor oil:

ND OIL 8 or equivalent4. EVACUATE AIR IN REFRIGERATION SYSTEM AND

CHARGE WITH REFRIGERANTSpecified amount:

850 50 g (29.98 1.76 oz)5. INSPECT FOR LEAKAGE OF REFRIGERANT6. INSPECT A/C OPERATION

AIR CONDITIONING SYSTEM RECEIVERAC46


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CONDENSER INSTALLATION1. INSTALL CONDENSER

Install the condenser with the 2 bolt.2. INSTALL LIQUID TUBES

Install both tubes with the 2 bolts.Specified torque: 9.8 Nm (100 kgfcm, 7 ftlbf)NOTICE: Do not remove caps until the tube is installed.

3. INSTALL COOLING FAN4. REPLENISH COMPRESSOR OIL IF CONDENSER

HAS BEEN REPLACEDAdd 40 cc (1.4 fl.oz.)Compressor Oil:

ND OIL 8 or equivalent5. EVACUATE AIR IN REFRIGERATION SYSTEM AND

CHARGE WITH REFRIGERANTSpecified amount:



7. INSTALL REMOVAL PARTSInstall the removal parts in reverse order of removalprocedure.

7. REMOVE CONDENSERRemove the 2 bolts and lean the radiator backward,then remove the cond enser.

AIR CONDITIONING SYSTEM CONDENSERAC48


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EVAPORATOR INSPECTION1. INSPECT FINS FOR BLOCKAGE

If the fins are clogged, clean them with compressedair.NOTICE: Never use water to clean the evaporator.

2. INSPECT FITTINGS FOR CRACKS OR SCRATCHESRepair as necessary.

EVAPORATOREVAPORATOR REMOVAL1. DISCHARGE REFRIGERANT FROM REFRIGERA


2. REMOVE BLOWER UNIT(See page AC35 )

3. REMOVE EVAPORATOR COVER(a) Remove 2 bolts for the liquid and suction tube.(b) Remove 8 screws and evaporator cover.

(b) Remove 2 bolts using a hexagon wrench and separatethe evaporator and expansion valve.

4. REMOVE EVAPORATOR(a) Pull and remove the evaporator.

AIR CONDITIONING SYSTEM EVAPORATORAC49


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EVAPORATOR INSTALLATION1. INSTALL REMOVAL PARTS

Install the removal parts in reverse order of removalprocedure.HINT:The tightening torque for the bolt used to install

the expantion valve on the evaporator is shownbelow.Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)The tightening torque for the bolts used to installthe liquid and suction tube is shown below.Torque: 9.8 Nm (100 kgfcm, 7 ftlbf)

2. REPLENISH COMPRESSOR OIL IF EVAPORATORHAS BEEN REPLACEDAdd 40 cc (1.4 fl.oz)Compressor oil:

ND OIL 8 or equivalent

3. EVACUATE AIR IN REFRIGERATION SYSTEM ANDCHARGE WITH REFRIGERANTSpecified amount:



AIR CONDITIONING SYSTEM EVAPORATORAC50


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HEATER RADIATOR INSTALLATION1. INSTALL HEATER RADIATOR TO A/C UNIT

(a) Put the radiator in the A/C unit.

(b) Connect teh heater pipes.(c) Install the 3 clamps with 3 screws.2. INSTALL HEATER PROTECTOR

HEATER RADIATOR

HEATER RADIATOR REMOVAL1. REMOVE HEATER PROTECTOR

Remove the 2 clips and the heater protector.

HEATER RADIATOR INSPECTIONIf the fin are clogged, clean them with commpressedair.

2. REMOVE HEATER RADIATOR

(a) Remove the 3 screws and the 3 clamps.

(b) Disconnect the heater pipes.(c) Pull the heater radiator out.

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WATER VALVE

WATER VALVE REMOVAL1. DRAIN ENGINE COOLANT FROM RADIATOR

HINT: It is not necessary to drain out all the coolant.2. DISCONNECT WATER VALVE CONTROL CABLE

FROM WATER VALVE

3. DISCONNECT WATER HOSE FROM WATER VALVE

3. CONNECT WATER VALVE CONTROL CABLE TO

WATER VALVE

(a) Set the temperature control switch to COOL.(b) Set the water valve lever to COOL, install the control

cable and lock the clamp.HINT: Lock the clamp while lightly pushing the outercable in the direction shown by the arrow.

WATER VALVE INSTALLATION1. INSTALL WATER VALVE

(a) Push the water hose onto the heater radiator pipe asfar as rigs on the pipe and install the hose clip.

(b) Install water valve with the bolt.2. CONNECT HEATER HOSE TO WATER VALVE

4. REMOVE WATER VALVE

(a) Disconnect the water hose from the heater radiatorpipe.

(b) Remove the bolt and the water valve

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ASV INSPECTION (5SFE ENGINEMODEL)1. CHECK VACUUM CIRCUIT CONTINUITY IN ASV BY

BLOWING AIR INTO PIPES(a) Connect the ASV terminals to the battery terminals as

illustrated.(b) Blow into pipe A and check that air comes out of

pipe B.

3. CHECK FOR OPEN CIRCUITUsing an ohmmeter, measure the resistance betweenthe 2 terminals.Resistance:

30 34 0 at 20

C (68

F)

If resistance value is not as specified, replace the ASV.

(c) Disconnect the battery.(b) Blow into pipe A and check that air does not come

out of pipe B.If a problem is bound, replace the ASV.

2. CHECK FOR SHORT CIRCUITUsing an ohmmeter, check that there is no continuitybetween each terminal and the ASV.If there is continuity, replace the ASV.

AIR SWITCHING VALVE (ASV)VACUUM HOSE CIRCUIT (5SFE ENGINEMODEL)

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BLOWER MOTOR INSTALLATION1. INSTALL MOTOR(a) Install the motor with the 3 screws.(b) Connect the connector.2. INSTALL CONNECTOR BRACKET3. INSTALL INSTRUMENT LOWER PANEL AND

UNDER COVER NO. 2

BLOWER MOTORBLOWER MOTOR REMOVAL1. REMOVE INSTRUMENT LOWER PANEL AND

UNDER COVER NO. 2(See page BO108 )

2. REMOVE CONNECTOR BRACKETRemove the 2 screws and the bracket

BLOWER MOTOR INSPECTIONINSPECT BLOWER MOTOR OPERATIONConnect the positive (+) lead from the battery toterminal 2 and the negative () lead to terminal 1,then check that the motor operation is smooth.

3. REMOVE MOTOR(a) Disconnect the connector.(b) Remove the 3 screws and the motor.

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CONDENSER FAN MOTORCONDENSER FAN MOTOR INSPECTION5SFE ENGINE MODEL:1. DISCONNECT CONNECTOR2. INSPECT CONDENSER FAN MOTOR

Connect positive (+) lead from battery and negative() lead to terminals, then check that the condenserfan motor operates smoothly.Standard current:

6.7 1 (A)

If current value is not as specified, replace the con denser fan motor.

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AIR INLET SERVOMOTOR INSPECTIONINSPECT SERVOMOTOR OPERATION

(a) Connect the positive (+) lead from the battery toterminal 1 and the negative () lead to terminal 2,check that the arm rotates to the FRESH side smoot hly.

AIR INLET SERVOMOTOR INSTALLATION1. INSTALL SERVOMOTOR(a) Install the servomotor with the 2 screws.(b) Connect the connector.2. INSTALL ECU AND ECU BRACKET3. INSTALL GLOVE COMPARTMENT

(b) Connect the positive (+) lead from the battery toterminal 1 and the negative () lead to terminal 3,check that the arm rotates to the RECI RC side smo othly.If operation is not as specified, replace the servomotor.

AIR INLET SERVOMOTORAIR INLET SERVOMOTOR REMOVAL1. REMOVE GLOVE COMPARTMENT

(See page BO108 )2. REMOVE ECU AND ECU BRACKET

3. REMOVE SERVOMOTOR(a) Disconnect the connector.(b) Remove the 2 screws and the servomotor.

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BLOWER RESISTORBLOWER RESISTOR REMOVAL1. REMOVE INSTRUMENT LOWER FINISH PANEL

(See page BO108 )2. REMOVE BLOWER RESISTOR(a) Disconnect the connector from the resistor.(b) Remove the 2 screws and the resistor.

BLOWER RESISTOR INSTALLATION1. INSTALL BLOWER RESISTOR(a) Install the resistor with the 2 screws.(b) Connect the connector to the resistor.2. INSTALL INSTRUMENT LOWER FINISH PANEL

If continuity is not as specified, replace the blower

resistor.

If continuity is not as specified, replace the blowerresistor.

INSPECT BLOWER RESISTOR CONTINUITYContinuity

BLOWER RESISTOR INSPECTION

Tester connectoin toterminal number


t 2356

Specified value

Specified value

1236 Continuity

Continuity

Condition

Condition

Constant

Constant

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Cooling Fan Control:(a) Connect the positive (+) lead from the ohmmeter to

terminal 2 and negative () lead to terminal 3.(b) Check continuity between terminals when refrigerant

pressure is changed, as shown.If operation is not as specified, replace the pressureswitch.

5. STOP ENGINE AND REMOVE MANIFOLD GAUGESET

6. CONNECT CONNECTOR TO PRESSURE SWITCH

PRESSURE SWITCHONVEHICLE INSPECTION1. INSTALL MANIFOLD GAUGE SET

(See page AC21 )2. DISCONNECT CONNECTOR FROM PRESSURE

SWITCH3. RUN ENGINE AT APPROX. 2000 RPM

Magnet Clutch Control:(a) Connect the positive (+) lead from the ohmmeter to

terminal 4 and negative () lead to terminal 1.(b) Check continuity between terminals when refrigerant

pressure is changed, as shown.If operation is not as specified, replace the pressureswitch.

4. INSPECT PRESSURE SWITCH OPERATION

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EVAPORATOR TEMPERATURE SENSORINSPECTION

Check resistance between terminals of evaporatortemperature sensor (thermistor) connector at eachtemperature.Resistance:

at 0 _ C (32 _ F): 4.6 5.1 k W

at 15 _ C (59 _ F): 2.1 2.6 k WIn addition as temperature increases, the resistancedecreases gradually.

EVAPORATOR TEMPERATURESENSOREVAPORATOR TEMPERATURE SENSORREMOVAL

REMOVE EVAPORATOR TEMPERATURE SENSORRemove the screw and the evaporator temperaturesensor (thermistor).

EVAPORATOR TEMPERATURE SENSORINSTALLATION

INSTALL EVAPORATOR TEMPERATURE SENSORInstall evaporator temperature sensor in reverse orderof removal procedure.

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3. INSPECT REVOLUTION DETECTING SENSORCheck the resistance between terminals 1 and 2 of thesensor.Specified resistance:

5SFE:165 205 W at 20 _ C (68 _ F)1 MZ FE:65 125 W at 20 _ C (68 _ F)

If the resistance value is not as specified, replace therevolution detecting sensor.

REVOLUTION DETECTING SENSORREMOVAL1. REMOVE COMPRESSOR

(See page AC37 )2. REMOVE REVOLUTION DETECTING SENSOR(a) Remove 2 bolts.(b) Remove the revolution detecting sensor.

REVOLUTION DETECTING SENSORONVEHICLE INSPECTION1. DISCONNECT NEGATIVE () CABLE FROM BAT

TERYCAUTION: Work must be started after 90 seconds fromthe time the ignition swithch is turned LOCK positionand the negative () terminal cable is disconnected fromthe battery.

2. DISCONNECT CONNECTOR OF REVOLUTION DETECTING SENSOR

REVOLUTION DETECTING SENSORINSTALLATION1. INSTALL REVOLUTION DETECTING SENSOR

Using a torque wrench, tighten the bolts.Torque:6 Nm (60 kgfcm, 4 ftlbf)

2. INSTALL COMPRESSOR(See page AC46 )

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RELAYRELAYS REMOVAL1. DISCONNECT NEGATIVE () CABLE FROM BAT

TERYCAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the LOCKposition and the negative () terminal cable is disconnected from the battery.

2. REMOVE RELAYS

RELAYS INSPECTION1. INSPECT MAGNET CLUTCH RELAY CONTINUITY

If continuity is not as specified, replace the relay.2. INSPECT A/C FAN RELAY NO. 2 CONTINUITY

5SFE Engine Model:

If continuity is not as specified, replace the relay.3. INSPECT A/C FAN RELAY NO. 3 CONTINUITY

5SFE Engine Model:

If continuity is not as specified, replace the relay.

Tester connection toterminal number



Apply6 + betweenterminals 1 and 4.

Apply B + betweenterminals 1 and 4.

Apply B + betweenterminals 1 and 4.

Specified value

Specified value

Specified value

1 43 5

Continuity

Continuity

Continuity

Continuity

Continuity

Continuity

Condition

Condition

Condition

Constant

Constant

Constant 1 4

1 4

2 3

2 3

2 3

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AIR CONDITIONING AMPLIFIER

A/C AMPLIFIER INSPECTIONINSPECT AMPLIFIER CIRCUIT

Disconnect the amplifier and inspect the connector onthe wire harness side, as shown in the chart below.Test conditions Ignition switch : ON Temperature control dial : MAX COOL Blower dial: HI

If circuit is not as specified, replace the amplifier.

Refrigerant pressure: less than 196 kPa ormore than 3140 kPa

Refrigerant pressure: 196 3140 kPa

Approx. 115 W at 20 _ C (68 _ F)

1.5 k W at 20 _ C (68 _ F)

Turn A/C switch OFF

Turn A/C switch OFF

Turn A/C switch OFF

Specified condition

Turn A/C switch ON

Turn A/C switch ON

Turn A/C switch ON

Tester connection

Battery voltage

Battery voltage

Battery voltage

Battery voltage

10 Ground

12 Ground

10 Ground

12 Ground

No voltage

No voltage

No voltage

No voltage

2 Ground

Continuity

8 Ground

8 Ground

5 Ground

2 Ground

Condition

Constant

Constant

Constant1413

913

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AIR CONDITIONING CONTROLASSEMBLYA/C CONTROL ASSEMBLY REMOVAL(See page BO108 )A/C CONTROL ASSEMBLY INSPECTION(ROTARY SWITCH AND PUSH BUTTONTYPE)

2. INSPECT MODE INDICATOR(a) Connect the positive (+) lead from the battery to

terminal A12 and the negative () lead to terminalA1.

(b) Push each of the mode bottons in and check that theirindicators light up.If operation is not as specified, replace the A/C con trol assembly.

1. INSPECT A/C INDICATOR(a) Connect the positive (+) lead from the battery to

terminal A12 and the negative () lead to terminalA4.

(b) Push the A/C button in and check that the indicatorlight up.If operation is not as specified, replace the A/C con trol assembly.

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4. INSPECT INDICATOR DIMMING OPERATION(a) Connect the positive (+) lead from the battery to

terminal A 12 and the negative () lead to terminalA 1.

(b) Connect the positive (+) lead from the battery toterminal A14 and check that the mode indicatordims.

If operation is not as specified, replace the A/C con trol assembly.

3. INSPECT AIR INLET INDICATOR(a) Connect the positive (+) lead from the battery to

terminal A 12 and the negative () lead to terminalA1.

(b) Check that the FRESH and RECIRC indicators light upalternately each time the air inlet control switchbutton is pressed.If operation is not as specified, replace the A/C con trol assembly.

If continuity is not as specified, replace the A/C con trol assembly.

5. INSPECT A/C SWITCH CONTINUITY

Tester connection toterminal numberSwitch position Specified value

No continuity

ContinuityA7 A8

OFF



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7. INSPECT AIR INLET CONTROL SWITCH CONTINUITY

If continuity is not as specified, replace the A/C control assembly.

If continuity is not as specified, replace the A/C con

trol assembly.

6. INSPECT MODE CONTROL SWITCH CONTINUITY



Switch position Specified value

Switch position Specified value

FOOT/ oeF

A11 Al

Continuity

Continuity

Continuity

Continuity

Continuity

Continuity

Continuity

A10 A1

A2 A 1

A3 A 1

A5 A 1

A9 A 1

A6A1

RECIRC

FRESH

FOOT

FACEB/L

D EF



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If continuity is not as specified, replace the switch.3. INSPECT BLOWER SPEED CONTROL SWITCH CON

TINUITY

2. INSPECT MODE CONTROL SWITCH CONTINUITY

If continuity is not as specified, replace the switch.

ROTARY SWITCH AND LEVER TYPE:

1. INSPECT A/C SWITCH CONTINUITY



Specified value

Specified value

Switch position

Switch position

No continuity

FOOT/ DEF

Continuity

Continuity

Continuity

Continuity

Continuity

Continuity

18

15

1 6

1 7

14

OFF.

FOOT

2 5

B/ LFACE

DEF



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A/C CONTROL CABLES ADJUSTMENT1. ADJUST AIR INLET DAMPER CONTROL CABLE

Set the air inlet damper and the control lever to FRESH position, install the control cable and lock theclamp.

2. ADJUST AIR MIX DAMPER CONTROL CABLESet the air mix damper and control switch to COOLposition, install the control cable and lock the clampwhile lightly pushing the outer cable in the directionshown by the arrow.

A/C CONTROL ASSEMBLYINSTALLATION

(See page BO108 )

If continuity is not as specified, replace the switch.

Switch position

Terminal

OFF



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SERVICE SPECIFICATIONSSERVICE DATA

TORQUE SPECIFICATIONS

Pressure switch x Liquired tube

Discharge hose x Compressor

Expansion valve x Evaporator

Magnetic clutch noT engaged

Magnetic clutch no engaged

Suction hose x Compressor

Magnetic clutch engaged

Refrigerant charge volume

Magnetic clutch clearance

Magnetic clutch engaged

Suction tube x A/C unit

Liquid tube x A/C unit

Compressor x Engine

Lequid x Condensor

Liquid x Receiver

Drive belt tention

Part tightened

Idle speed

1 MZ FE:

1 MZ FE:

Used belt

Used belt

New belt

New belt5SFE:

5SFE:

AIR CONDITIONING SYSTEM SERVICE SPECIFICATIONSAC73

Air Conditioning System –

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